Professional Documents
Culture Documents
00/2003-10
www.serviceaprilia.com
workshopmanual
USA
8140742
INTRODUCTION 0
0-1
SUMMARY
0.1. INTRODUCTION ............................................................................................................................................. 3
0.1.1. INTRODUCTION.................................................................................................................................... 3
0.1.2. REFERENCE MANUALS....................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5
0-2
0.1. INTRODUCTION
0.1.1. INTRODUCTION
- This manual provides the information required for normal servicing.
- This publication is intended for use by Aprilia dealerships and their qualified mechanics; many concepts have been
omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical expla-
nations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well
as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazard-
ous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to prevent
damage and injury. To ensure maximum customer satisfaction with the vehicle, Aprilia S.p.A. continuously im-
proves its products and their documentation. The main technical modifications and changes in repair procedures
are communicated to all Aprilia dealerships and agencies worldwide. Such modifications will be supplied in subse-
quent editions of the manual. In case of doubt regarding specific repairs or checks, contact the Aprilia SERVICE
DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you up-
dated on changes and modifications to the vehicle.
Aprilia S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may alter
the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
Aprilia S.p.A. is not liable in any way for the performance or use of their products.
DECA srl
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
Aprilia S.p.A.
Via G. Galilei, 1 – 30033 Noale (VE) – Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0-3
PARTS CATALOGUES
Aprilia part# (description)
3974
OWNER’S MANUALS
Aprilia part# (description)
8104334
8104691
8104692
8104693
8104704
8104694
8104695
0-4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = less than or equal to
≥ = more than or equal to
~ = approximately
∞ = infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
AC = alternating current
A = Ampere
Ah =Ampere per hour
API = American Petroleum Institute
HV = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC. = Direct Current
cc = cubic centimeters
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
Kg = kilograms
Kgm = kilogram meter (1 kgm =10 Nm)
km = kilometers
kph = kilometers per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kiloWatt
l = liters
LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE = left side
m/s = meters per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton meter (1 Nm =0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Center
TDC = Top Dead Center
PPC = Pneumatic Power Clutch
0-5
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
TP = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork
V = Volt
W = Watt
Ø = Diameter
0-6
GENERAL INFORMATION 1
1-1
SUMMARY
1.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
1.1.2. SAFETY WARNINGS............................................................................................................................. 4
1.2. GENERAL RULES........................................................................................................................................... 5
1.2.1. BASIC SAFETY RULES......................................................................................................................... 5
1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8
1.3.1. WARNINGS ........................................................................................................................................... 8
1.4. RUNNING-IN ................................................................................................................................................. 12
1.4.1. RUNNING-IN RECOMMENDATIONS.................................................................................................. 12
1.5. VEHICLE IDENTIFICATION .......................................................................................................................... 13
1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 13
1.6. POSITION OF THE WARNING ADHESIVE LABELS.................................................................................... 15
1.6.1. POSITION OF THE WARNING ADHESIVE LABELS .......................................................................... 15
1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM .......................................................................... 25
1-2
optional
catalytic version
- all versions
MP national certification
SF European certification (EURO 1 limits)
VERSION:
Italy Greece Malaysia
United Holland Chile
Kingdom
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan United
States of
America
Belgium Singapore Brazil
Germany Slovenia South Africa
France Israel New
Zealand
Spain South Canada
Korea
1-3
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in very serious risks for your and other people's safety and for the vehicle!
WARNING
Indicates a potential hazard which may result in serious injury or even death.
CAUTION
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.
1-4
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death by asphyxia.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular conditions.
Refueling and engine service should take place in a well-ventilated area with the engine turned off. Do
not smoke when refueling or in the proximity of sources of fuel vapors, avoid flames, sparks and any
element that could ignite fuel or provoke explosions.
HIGH-TEMPERATURE COMPONENTS
The engine and the exhaust system parts become hot and continue to be hot even for some time after the engine has
been stopped.
Before handling these parts, wear insulating gloves or wait for the engine and the exhaust system to cool completely
down.
DANGER
In case any maintenance operation should be required, it is advisable to use latex gloves.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation should be required, it is advisable to use latex gloves.
BRAKE FLUID
WARNING
When using the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it can
damage them.
When carrying out the maintenance operations on the braking system, use a clean cloth to cover these
parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with the skin or the eyes, carefully wash the parts of your body that get
in contact with the fluid and consult a doctor.
1-5
COOLANT
The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send forth
invisible flames causing severe burns.
DANGER
Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch
fire and send forth invisible flames.
In case any maintenance operation should be required, it is advisable to use latex gloves.
Even if toxic, coolant has a sweet flavor. Never leave it inside open containers or within the reach of
animals to prevent the risk of drinking.
Do not remove the radiator plug when the engine is hot. The coolant is under pressure and could cause
severe burns.
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Always wear tight gloves and protective clothes when handling this fluid.
If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact
with the fluid with abundant fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and
then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink milk of magnesia or
vegetable oil and consult a doctor immediately. The battery releases explosive gases. Keep flames,
sparks, cigarettes and any other heat source away from it. Make sure the room is well aerated when
servicing or recharging the battery.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting
the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and
exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on
firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to
the touch to avoid scalds or burns.
Never put any mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components is edible. Some components are harmful to the human body
or toxic.
Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing
the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the
manual, proceed sensibly to prevent shifting any parts unless strictly necessary. Never attempt to polish
matte-finished surfaces with lapping compounds.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, gasoline or solvents. Clean with water
and neutral detergent.
Always disconnect the battery negative (–) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
1-6
DANGER
Never reuse a circlip or snap ring. These parts must always be replaced once they have been shifted.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitting
in the shaft.
Make a rule to check that a newly –fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL Aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten e-
venly in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then drive the
motorcycle in a private estate area or in a safe area away from traffic.
- Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to
irreparable damages to the connector and the wiring as well. If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, and so on, thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connectors’ terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.
Then fit the two connectors. Make sure they are correctly coupled (a click will be heard).
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
handling, and thus the risk of falls and serious injuries or death.
1-7
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular conditions.
Refueling and engine service should take place in a well-ventilated area with the engine turned off. Do
not smoke when refueling or when near fuel vapors’ sources. Avoid contact with bare flames, sources of
sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In the
event of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel
expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refueling.
Avoid contact with skin. Do not inhale vapors. Do not swallow fuel. Do not use a hose to transfer fuel be-
tween different containers.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP IT AWAY FROM CHILDREN.
Use only premium grade unleaded gas, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle’s safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type
of lubricant can lead to the engine’s or gearbox’s seizure, thus leading to serious accidents, personal in-
jury or even death.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil into the environment.
Take it to the filling station where you usually buy it or to an oil salvage center.
WARNING
When filling the vehicle with this oil, take care not to spill it out since it could damage the vehicle paint-
work.
In case of contact with oil, the tires’ surface will become very slippery, thus becoming a serious danger
for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not release it into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.
DANGER
Front suspension response can be modified to a certain extent by changing the damping settings and/or
selecting a particular grade of oil. Standard oil grade is SAE 20 W. Different oil grades can be selected to
obtain a particular suspension response. (Choose SAE 5W for a softer suspension, 20W for a stiffer sus-
pension).
The two grades can also be mixed in varying solutions to obtain the desired response.
1-8
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that
most ensure your safety and for this reason they must always be in perfectly working order. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent risk
of personal injury or death.
A wet surface reduces the brakes’ efficiency.
DANGER
In case of wet ground, double the braking distance since both brakes and tires drives on the road surface
are extremely reduced by the water present on the road’s surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface, crossing puddles or
ditches can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk of
severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for the brakes’ proper working order before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash the affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT. KEEP IT AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers that have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the hy-
draulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entry of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be in per-
fectly working condition; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or on racetracks.
When the disc pads wear out, the level of the fluid decreases to automatically compensate for their wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system is leaking fluid.
1-9
COOLANT
DANGER
Coolant is toxic when ingested; it is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the
event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice
immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP IT AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear la-
tex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited for the warm season, as it is less prone to evaporative loss and will reduce the need for top-
ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the cool-
ing system’s efficiency.
When temperature drops below zero degrees centigrade, check the cooling system frequently and add more anti-freeze
(up to 60% maximum) to the solution.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing
point:
NOTE Coolants have different specifications. The protection degree is written on the label.
WARNING
Use nitrate-free coolant only, with a protection until at least -31°F (-35°C).
DRIVE CHAIN
Check the drive chain operation, slack and lubrication at regular intervals.
The vehicle is equipped with an endless chain with a joint link.
WARNING
If too slack, the chain can come off the front or rear sprockets thus leading to serious accidents and
damage to the vehicle, with consequent serious personal injury or death.
Do not use the vehicle if the chain tension has not been correctly adjusted.
To check the chain, take it with your hand where it turns on the rear sprocket and pull it as to separate it
from the crown itself.
If you can move the chain apart of the front sprocket for more than 0.125 in (3 mm), change chain, crown
and pinion.
DANGER
If not properly maintained, the chain can undergo early wear out and lead to the damage of both crown
and pinion.
Perform chain maintenance operations more frequently if the vehicle is used on rainy or dusty areas.
1 - 10
TIRES
WARNING
If tires are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at
your ease.
In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tires (insufficient pressure) can slip on the rim and make you lose control of the vehicle.
In this case too, both vehicle roadworthiness, handling and brake efficiency will be impaired.
Tires changing, repair, maintenance and balancing must be carried out by specialized technicians using
suitable equipment.
When new, tires can have a thin slippery protective coating. Drive carefully for the first kilometers (miles).
Never use rubber treating substances on tires.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change tires.
DANGER
Some of the factory-assembled tires of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tires are worn and in this case have them changed.
If a tire deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close throttle grip, move to the edge of the road and use the engine brake to slow down until com-
ing to a halt.
Failure to comply with these recommendations can lead to serious accidents and consequent personal
injuries or death.
Do not install tires with air tube on rims for tubeless tires and vice versa.
1 - 11
1.4. RUNNING-IN
1.4.1. RUNNING-IN RECOMMENDATIONS
Running-in the engine is essential to ensure its duration and correct functioning.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un-
dergo a more effective running-in.
During the running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine’s parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to over do it.
WARNING
You can expect the best performance levels from the vehicle only after the first 932 mi (1500 km) of run-
ning-in.
WARNING
After the first 621 mi (1000 km), Dealers carry out the checks indicated in the column "After running-
in", see (REGULAR SERVICE INTERVALS CHART), in order to avoid hurting yourself or other people
and/or damaging the vehicle.
• Between the first 621 mi (1000 km) and 932 mi (1500 km) drive more briskly, change speed and use the maximum
acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 7500 rpm
(see table).
• After the first 932 mi (1500 km) you can expect better performance from the engine, however, without exceeding
the maximum allowed [11000 rpm].
1 - 12
ENGINE NUMBER
The engine number (2) is stamped on the rear part of the
engine, near the pinion.
1 - 13
DIGIT MEANING
1. Manufacturer’s identification alphanumeric code.
2. Vehicle type.
3. Model.
4. Country for which the vehicle is intended.
5. #= Check digit number.
6. Model year.
7. Assembling factory designation
(N = NOALE-VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).
8. Sequential serial number.
1 - 14
1 - 15
1 - 16
10
1 - 17
11
12
13
14
1 - 18
14a
15 Muffler stamping
1 - 19
1 - 20
1 - 21
10
11
12
1 - 22
13
14
15
15a
1 - 23
16 Muffler stamping
1 - 24
1 - 25
2-1
SUMMARY
2.1. GENERAL TECHNICAL INFORMATION ........................................................................................................ 3
2.1.1. TECHNICAL DATA ................................................................................................................................ 3
2.1.2. PERIODIC MAINTENANCE CHART...................................................................................................... 7
2.1.3. TABLE OF LUBRICANTS ...................................................................................................................... 9
2.1.4. TIGHTENING TORQUES .................................................................................................................... 10
2.1.5. SPECIAL TOOLS ................................................................................................................................. 14
2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS ..................................................................................... 21
2.1.7. ARRANGEMENT OF THE INSTRUMENTS/CONTROLS.................................................................... 25
2.1.8. DASHBOARD OPERATION ................................................................................................................ 26
2.1.9. SYSTEMS DIAGRAM .......................................................................................................................... 34
2-2
ENGINE
Model V990 NG
Type 4-stroke V 60* twin-cylinder, with 4 valves per cylinder, DOHC.
No. of cylinders 2
3 3
Total displacement 60.902 in (998 cm )
Bore/stroke 3.819 in/2.657 in (97 mm/67,5 mm)
Compression ratio 11,8 ± 0,4: 1
Starting Electric starter
Engine idling speed 1280 ± 100 rpm
Clutch Multiplate wet clutch, hydraulically operated, control on left side of han-
dlebar and PPC device
Lubricating system Dry sump with separate oil tank and oil cooler
Air cleaner Dry filter cartridge
Cooling system Liquid coolant
GEARBOX
Type Mechanical, 6 gears with foot control on engine’s left side
CAPACITIES
Fuel (including reserve) 4.755 gal (18 l)
Fuel reserve 1.189 ± 0.264 gal (4,5 ± 1 l)
Engine oil Oil change 225.788 in3 (3700 cm3) - oil and oil filter change 237.993 in3
(3900 cm3)
3 3
Front fork oil RSV R 31.732 ± 0.152 in (520 ± 2,5 cm ) (each leg)
Front fork “R FACTORY” RFACT (RSV R 30.512 ± 0.152 in3 (500 ± 2,5 cm3) (each leg)
OPT) oil
Coolant 0.581 gal (2,2 l) (50% water + 50% anti-freeze with ethylene glycol)
Seat 2 (RFACT USA version: single-seater only)
Max. load RSV R 396.832 lb (180 kg) (rider + passenger + luggage) – RFACT
USA 231.485 lb (105 kg)
TRANSMISSION RATIOS
Ratio Primary Secondary Final drive Total ratio
1st 31/60 = 1: 1,935 15/34 = 1: 2,267 16/40 = 1: 2,500 1:10,968
2nd 19/31 = 1: 1,632 1:7,895
3rd 20/26 = 1: 1,300 1:6,290
4th 22/24 = 1: 1,091 1:5,279
5th 25/24 = 1: 0,960 1:4,645
6th 26/23 = 1: 0,885 1:4,280
DRIVE CHAIN
Type Endless (with no master link) with O-ring links
Endless 525
FUEL SYSTEM
Type Electronic injection (Multipoint)
Choke Ø 2.244 in (Ø 57 mm)
FUEL
Fuel Premium-grade unleaded gas, minimum octane rating 95 (ROM) and 85
(MON).
2-3
FRAME
Type Two-beam frame with light alloy cast elements and extruded elements
Steering head angle 25°
Trail 3.937 in (100 mm) (with 120/70 front tire)
SUSPENSION
Front Adjustable hydraulic upside-down fork, Ø 1.693 in (Ø 43 mm)
Travel RSV R 4.999 in (127 mm) – RFACT (RSV R OPT) 4.724 in (120 mm)
Rear Light-alloy swinging arm with differentiated profiles on both sides and adjustable air/oil-
sprung mono-shock absorber
Wheel travel 5.31 in (135 mm)
BRAKES
Front Twin floating disk - Ø 12.598 in (Ø 320 mm), four-piston calipers - Ø 1.338 in (Ø 34 mm)
Rear Disk brake - Ø 8.661 in (Ø 220 mm), twin-piston caliper - Ø 1.260 in (Ø 32 mm)
WHEEL RIMS
Type Light alloy, spindle can be removed
Front 3,50 x 17"
Rear 6,00 x 17"
2-4
TIRES
Pressure kPa (bar)
Recom- # $
Wheel Make Model Type Size Alternative
mended Rider and
Rider Rider
passenger
** Front PIRELLI DIABLO CORSA 120/70– # $ RSV R + R 230 (2,3) 250 (2,5) 210
ZR 17" FACT (2,1)
** Rear PIRELLI DIABLO CORSA 190/50– # $ RSV R + R 250 (2,5) 280 (2,8) 200
ZR 17" FACT (2,0)
* Front PIRELLI DRAGON – 120/70– # $ RSV R + R 230 (2,3) 250 (2,5) 210
SUPER- ZR 17" FACT (2,1)
CORSA
* Rear PIRELLI DRAGON – 180/55– # $ RSV R + R 250 (2,5) 280 (2,8) 200
SUPER- ZR 17" FACT (2,0)
CORSA
** Front METZELER SPORT- M1 120/70– # $ RSV R + R 230 (2,3) 250 (2,5) 210
TEC ZR 17" FACT (2,1)
Rear METZELER SPORT- M1 180/55– # $ RSV R + R 250 (2,5) 280 (2,8) 200
TEC ZR 17" FACT (2,0)
** Rear METZELER SPORT- M1 190/50– # $ RSV R + R 250 (2,5) 280 (2,8) 200
TEC ZR 17" FACT (2,0)
Front METZELER RENNSPO – 120/70– - $ RSV R + R - - 210
RT ZR 17" FACT (2,1)
Rear METZELER RENNSPO – 180/55– - $ RSV R + R - - 200
RT ZR 17" FACT (2,0)
** Front DUNLOP SPORT- D 208 120/70– # - RSV R+ 230 (2,3) 250 (2,5) -
MAX ZR 17" RFACT
** Rear DUNLOP SPORT- D 208 190/50– # – RSV R+ 250 (2,5) 280 (2,8) –
MAX ZR 17" RFACT
Front DUNLOP SPORT- D 208 120/55– - $ RFACT - - 210
MAX RR ZR 17" (2,1)
Rear DUNLOP SPORT- D 208 180/55– - $ RFACT - - 190
MAX RR ZR 17" (1,9)
* = standard RFACT **= standard RSV R # = Standard use $= Racing use
2-5
SPARK PLUGS
Standard NGK R DCPR9E
Electrode gap 0.024– 0.028 in (0,6 – 0,7 mm)
Resistance 5 kΩ
ELECTRIC SYSTEM
Battery 12 V – 10 Ah
Main fuses 30 A
Auxiliary fuses 5 A, 15 A, 20 A
Generator (permanent-wound type) 12 V – 500 W
BULBS
Low beam (halogen) 12 V – 55 W H7U x 2
High beam (halogen) 12 V – 55 W H7U x 2
Front parking light 12 V – 5 W
Direction indicators 12 V – 10 W
Number plate light 12 V – 5 W
Stop/rear parking lights LED
Rev counter light LED
Left multifunction display LED
WARNING LIGHTS
Neutral LED
Direction indicators LED
Fuel reserve LED
High beam LED
Stand down LED
General warning LED
Red line LED
Immobilizer LED
2-6
Key
1= check and clean, adjust, lubricate or replace, if necessary;
2= clean;
3= replace
4= adjust.
2-7
Key
1= check and clean, adjust, lubricate or replace, if necessary;
2= clean;
3= replace
4= adjust.
(*) = only for versions with magnesium wheels: check that rim paint is in good conditions.
NOTE Halve the maintenance intervals if the vehicle is used in rainy or dusty conditions, on rough roads or for racing.
2-8
LUBRICANT PRODUCT
2-9
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
ENGINE
2 - 10
FRONT SUSPENSION
Front fork
Fork leg on top yoke 1+1 M8 18,439 -
Fork leg on bottom yoke 2+2 M8 18,439 -
tighten first
Head stock nut (tighten first, then slacken) 1 M35x1 29,502 and then
slacken
tighten 2nd
Head stock nut (tighten down 2nd time) 1 M35x1 14,751
time
man. + 90
Head stock locknut 1 M35x1 -
grade
Top yoke cap 1 M29x1 73,756 -
SHOWA fork hub clamps 2+2 M8 18,226 -
OHLINS fork hub clamps 2+2 M6 8,851 -
Steering damper
Steering damper collar to frame 1 M6 7,376 Loctite 243
Steering damper rod on bottom yoke 1 M6 7,376 -
REAR SUSPENSION
Shock absorber
Shock absorber to frame 1 M10 36,878 -
Linkages
Single conrod to frame 1 M10 36,878 -
Single / double conrod 1 M10 36,878 -
Double conrod swinging arm 1 M10 36,878 -
Double conrod / shock absorber 1 M10 36,878 -
ELECTRICAL SYSTEM
Battery cover bracket 2 M5 1,475 -
Horn mount / bracket 1 M8 18,439 -
Odometer sensor on rear brake caliper support 1 M6 8,851 -
Rear direction indicators 2 M4 0,738 -
Front direction indicators / rear view mirrors 2+2 M6 3,688 -
Voltage regulator 2 M6 3,688 -
Coil to bracket support 1 M6 7,376 -
Tail light to rear fairing end 4 M5 0,738 -
Head lamp to front fairing 6 SWP5x14 1,475 -
Relay box to seat subframe 2 M6 2,213 -
Relay cable to starter motor 1 M6 3,688 -
Relay cable 2 M6 1,475 -
FRONT WHEEL
Wheel axle nut 1 M25x1,5 59,005 -
REAR WHEEL
Sprocket / Sprocket carrier 5 M10 36,878 -
Wheel axle nut 1 M25x1,5 88,507 -
2 - 11
COOLING SYSTEM
Fan support 2+2 M6 4,425 -
Expansion reservoir to frame 2 M6 3,688 -
Expansion reservoir cap 1 M28x3 man. -
Hose clips (8104097) - - 2,213 -
BRAKE SYSTEM
Front brakes
Right and left brake calipers 2+2 M10x1,25 36,878 -
Brake fluid reservoir to bracket 1 M6 5,163 -
Brake fluid reservoir to bracket support 1 M5 7,376 -
Brake disc 1 M8 22,127 -
Front brake three-way fitting bracket 6+6 M5 2,213 Loctite 243
Rear brakes
Brake caliper 2 M8 18,439 -
Brake lever pin 1 M8 11,036 Loctite 243
Brake fluid reservoir 1 M5 0,738 -
Brake shaft locknut 1 M6 man. -
Brake disc 5 M8 22,127 Loctite 243
Front brake hose three-way bracket 1 M5 2,213 -
EXHAUST SYSTEM
Front exhaust hose to engine 4 M6 8,851 -
Fasten by
Rear exhaust hose to engine (upper screws) 2 M6 -
hand
Rear exhaust hose to engine (lower screws) 2 M6 8,851 -
Lambda sensor 1 M18x1,5 28,027 -
FUEL TANK
2 - 12
2 - 13
CAUTION
Before using the special tools, consult any documents attached.
SUPPORT STANDS
xxxxxxx N.A. = available only with the Aprilia kit part# 8140176 (complete support stand kit)
2 - 14
FRAME TOOLS
FORK TOOLS
2 - 15
ENGINE TOOLS
2 - 16
2 - 17
MISCELLANEOUS TOOLS
2 - 18
2 - 19
2 - 20
KEY RSV R
1. Left side fairing
2. Adjustable steering damper RSV R OPT
3. Headlight left lamp
4. Front fairing
5. Left rear-view mirror
6. Clutch fluid’s reservoir
7. Engine’s oil filter
8. Left side panel
9. Rider’s seat
10. Battery
11. Main fuse carrier (30 A)
12. Passenger seat’s lock glove/tool kit compartment
13. Passenger left footrest (snaps closed/open)
14. Drive chain
15. Rear swinging arm
16. Rider’s left footrest
17. Side stand
18. Gear shift lever
19. Engine’s oil tank
20. Engine’s oil level
21. Engine oil tank’s cap
2 - 21
KEY RSV R
1. Rear shock absorber
2. Passenger right footrest (snaps closed/open)
3. Tail light
4. Glove/tool kit compartment
5. Passenger seat (glove/tool kit’s compartment cover)
6. Passenger’s grab strap
7. Engine’s Control Unit
8. Right side panel
9. Fuel tank
10. Coolant expansion tank’s cap
11. Fuel tank’s filler cap
12. Air cleaner
13. Right rear-view mirror
14. Front brake fluid’s reservoir
15. Secondary fuse carrier (15 A)
16. Horn
17. Right side fairing
18. Expansion tank
19. Rear brake fluid’s reservoir
20. Rear brake master’s cylinder
21. Rear brake’s lever
22. Rider’s right footrest
2 - 22
PRINCIPALI
KEY RFACT
1. Left side fairing
2. Adjustable steering damper
3. Headlight left lamp
4. Front fairing
5. Left rear-view mirror
6. Clutch fluid’s reservoir
7. Engine’s oil filter
8. Left side panel
9. Rider’s seat
10. Battery
11. Main fuse carrier (30A)
12. Passenger seat-Glove/tool kit’s compartment lock
13. Passenger’s left footrest
14. Drive chain
15. Rear swinging arm
16. Rider’s left footrest
17. Side stand
18. Gear shift lever
19. Engine’s oil tank
20. Engine’s oil level
21. Engine oil tank’s cap
2 - 23
KEY RFACT
1. Rear shock absorber
2. Passenger’s right footrest (snaps closed/open)
3. Tail light
4. Glove/tool kit’s compartment
5. Passenger seat (Glove/tool kit’s compartment cover)
6. Passenger’s grab strap
7. Engine’s Control Unit
8. Right side panel
9. Fuel tank
10. Coolant expansion tank’s cap
11. Fuel tank filler’s cap
12. Air cleaner
13. Right rear-view mirror
14. Front brake fluid’s reservoir
15. Secondary fuse carrier (15A)
16. Horn
17. Right side fairing
18. Coolant expansion tank
19. Rear brake fluid’s reservoir
20. Rear brake’s master cylinder
21. Rear brake’s lever
22. Rider’s right footrest
2 - 24
Key:
1. Clutch lever
2. Ignition/steering lock switch ( - - )
3. Instruments and indicators
4. Front brake lever
5. Throttle twistgrip
6. High beam flasher ( )/LAP button (multifunction)
7. Light dimmer switch ( - )
8. Direction indicator switch ( )
9. Horn button ( )
10. Starter button ( )
11. Engine kill switch ( )
Key:
1. Rev counter
2. Red line light
3. Green direction indicator light ( )
4. Blue high beam light ( )
5. Amber "stand down" light ( )
6. Amber low fuel light ( )
7. Red immobilizer light ( ) (where immobilizer system
is fitted)
8. Green neutral light (N)
9. Multifunction digital display (coolant temperature - clock
- battery voltage - lap timer - engine oil pressure
diagnostics ( )
10. Red general warning light ( )
11. Multifunction computer programming buttons
(+, Trip V, -)
2 - 25
WARNING
If “ERR” flashes on the dashboard instead of the
water temperature reading and if the stand and
red line leds turn on, then there is a communi-
cations problem on the can line between the
dashboard and the ECU.
After the first 1000 Km, the SERVICE icon will
be displayed on the multifunction display. It will
be displayed for a second time after 10,000 Km,
and every 10,000 Km thereafter.
To reset the SERVICE message, hold down the
+ and – keys for at least 15 seconds at key-ON.
2 - 26
2 - 27
WARNING
If the coolant temperature sensor is discon-
nected or damaged, the dashboard error led
turns on ( ) and the coolant temperature is not
read.
2 - 28
HOURS SETTING
• Hold down the + and – keys for at least 3 seconds so
that the hour digits start to flash.
• Use the + and – keys to set the hour.
• If one of the keys is held down, the setting will run
through the hours one a second.
• Hold down the TRIP/V key for at least 3 seconds to
confirm the new setting. The clock will automatically
move to the minutes setting mode.
MINUTES SETTING
• Press the + or – key to increase/decrease the minute
setting. If one of the keys is held down, the setting runs
through the minutes one a second.
• Hold down the TRIP/V key for at least 3 seconds, at
which point the minute digits will stop flashing to indi-
cate that the new setting is confirmed.
• The clock setting is lost when the battery is discon-
nected from the vehicle.
CHRONOMETER
The chronometer measures the lap time when driving on
track and stores the data for later reference.
When the chronometer is enabled, the clock function is ex-
cluded.
To activate the chronometer :
• Hold down the LAP button and press TRIP/V for more
than 3 seconds. The clock display will be replaced by
“01 LAP 00’00”00 ”.
To de-activate the chronometer :
• Hold down the LAP button and press TRIP/V for more
than 3 seconds. The clock display will return.
2 - 29
DIAGNOSTICS
Whenever the ignition key is turned to “ ”, “EFI” is displayed
for 3 seconds.
WARNING
If “EFI” displays together with the warning led
( ) while the engine is running normally, the
ECU has detected a fault.
In most cases the engine will continue to oper-
ate although with reduced performance.
WARNING
If the engine oil pressure icon stays on together
with the warning led ( ), after starting, or if it
turns on while the engine is running normally,
the engine oil pressure is insufficient.
In this case, stop the engine immediately.
2 - 30
To adjust :
• Turn the ignition key to “ ”.
• Wait for the self-check to complete.
• Press TRIP/V for more than 3 seconds: the revolution
counter pointer (1) will move to the set red line value.
• The red line setting can be adjusted during the 3 sec-
onds that the revolution counter pointer (1) is indicating
the set value.
• Adjust the red line setting with the + key: pressing it
briefly will increase the setting by 100 rpm; holding it
down will increase it by 1000 rpm.
• If the pointer reaches the full-scale value (12000 rpm) it
is automatically reset to zero.
Display type :
water temperature digits together with EFI icon and warning
led ( ). When a diagnostics code is displayed, the water
temperature’s symbol (thermometer), units’ indication (°C/°F)
and display segments disappear.
Operating modes :
In normal conditions, the “EFI” icon and warning led ( ) are
off. If one or more Fault Codes are sent to the dashboard by
the ECU, the dashboard will not display them; it will only turn
on the warning led ( ) and “EFI” icon instead.
2 - 31
2 - 32
SERVICE INTERVALS
2 - 33
BRAKES
2 - 34
2 - 35
FUEL SYSTEM 3
3-1
SUMMARY
3.1. FUEL SYSTEM................................................................................................................................................ 3
3.1.1. DIAGRAM .............................................................................................................................................. 3
3.1.2. INJECTION SYSTEM DIAGRAM ........................................................................................................... 4
3.1.3. CYLINDER TIMING AND CO LEVEL ADJUSTMENT............................................................................ 6
3.1.4. AXONE................................................................................................................................................... 7
3.1.5. AIRBOX................................................................................................................................................ 11
3.2. FUEL PUMP .................................................................................................................................................. 12
3.2.1. REMOVING THE FUEL PUMP ASSEMBLY........................................................................................ 12
3.2.2. REMOVING THE FUEL LEVEL SENSOR ........................................................................................... 13
3.2.3. REMOVING THE DELIVERY FILTER.................................................................................................. 14
3.2.4. REMOVING THE FUEL SUPPLY PUMP ............................................................................................. 15
3.3. THROTTLE BODY......................................................................................................................................... 17
3.3.1. REMOVING THE THROTTLE BODY................................................................................................... 17
3.3.2. DISASSEMBLING THE THROTTLE BODY......................................................................................... 20
3.3.3. INSPECTING THE THROTTLE BODY ................................................................................................ 23
3.3.4. REFITTING THE THROTTLE BODY ................................................................................................... 24
3.3.5. REPLACING THE THROTTLE VALVE CONTROL LEVER................................................................. 26
3.3.6. CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY ........................................................ 27
3-2
Key
1) Fuel tank
2) Filler cap
3) Fuel supply pump unit
4) Fuel vapor breather pipe (for the vapors produced by excessive pressure inside the tank)
5) Fuel “overflow” drainage pipe
6) Fuel level sensor
7) Fuel delivery filter
8) Fuel supply pump
9) Fuel delivery pipe
10) Fuel return pipe
3-3
3-4
Legend :
1. ECU location
2. Ignition switch
3. Battery
4. Engine shaft position sensor
5. Camshaft position sensor
6. Engine temperature sensor
7. Air temperature sensor
8. Throttle position sensor
9. Intake pressure sensor
10. Safety system: Side stand, idle sensor
11. Test switch
12. Fall sensor
13. Atmospheric pressure sensor
14. Oil pressure sensor
15. Fan
16. Automatic air
17. Intake flap
18. Lambda sensor
19. Diagnostics connector
20. Starter relay
21. Fuel pump
22. Injector 1
23. Injector 2
24. Coil
3-5
• Read the front and rear cylinder pressure values off the
Axone, and check that they are as follows :
front cylinder pressure = rear cylinder pressure –
(30 ± 10) mbar
3-6
3.1.4. AXONE
ICON DISPLAY
ISO
DEVICE ACTIVATION
ERRORS DISPLAY
ADJUSTABLE PARAMETERS
UNITS
VALUES OF
DISPLAY DESCRIPTION NOTES
(APPROXIMATE) MEASURE-
MENT
ISO Aprilia hardware
Aprilia software
Revision number
Engine
Manufactured
Mapping Indicates the ECU mapping code
Date programmed Most recent mapping date
Last author ID of PC/Axone which loaded the most
recent mapping
ENGINE Water temperature °C Fans are activated at 101°C
PARAMETER
READING
Air temperature °C
Engine speed rpm
Target minimum engine rpm ECU target engine speed for current
speed operating conditions
Engine load -
Intake pressure hPa Value read by sensor connected to the
two intake ducts
Effective 2,7-80 ° Parameter which accounts for the throt-
throttle tle aperture and stepper motor position
aperture
Spark advance °
Throttle 0-78° ° Reads the throttle aperture in degrees
Throttle offset approx. V Reference after reset (ECU stored
0,60- 0,63 value)
Idling control stepper motor - Steps of idling control motor
Battery voltage V
Vehicle speed kph
Cylinder pressure hPa Intake duct pressure
(front)
Cylinder pressure hPa Intake duct pressure
(rear)
Lambda correction - Approx. 1 with lambda sensor active
3-7
Injection time ms
Atmospheric pressure hPa Sensor located under seat
Spark advance °
DEVICE Fall sensor normal/
STATUS tip over
Ignition request on/off Thus can be seen with the gear en-
gaged by pressing the starter button: in
this condition the ECU reads the igni-
tion permissive (Axone reads ON) but
does not start the engine. For instance,
if the right dimmer switch circuit is inter-
rupted, although the ignition button is
pressed, the condition of this parameter
does not change (it stays OFF)
Purge valve on/off
Lambda sensor active on/off Lambda sensor operational
Cut off on/off Activates at certain engine speed /
throttle position etc. combinations
Throttle self-teaching com- on/off If throttle position self-teaching does
pleted not end successfully, the parameter =
OFF
Lambda sensor initialization / wait after start / sen- Lambda sensor status
3-8
3-9
3 - 10
3.1.5. AIRBOX
Key:
1. Throttle body
2. Front air intake
3. Check valve
4. Membrane
5. Solenoid valve
6. Vacuum chamber
7. Atmospheric pressure
Air intake is controlled by a flap in the duct leading from the windshield to the airbox.
This flap reduces engine noise at low engine speeds.
The flap assembly is composed of: hatch / tie-rod / membrane / solenoid valve
The flap is normally closed and opens in the following circumstances:
minimum 6500 rpm
minimum 30 % throttle opening
3 - 11
WARNING
When removing the pump assembly make sure
not to damage the fuel hoses and level sensor.
3 - 12
3 - 13
CAUTION
Do not use filters that have already been used.
3 - 14
CAUTION
Upon installation, replace the hose clamp that
has been removed with a new one having the
same dimensions.
Do not attempt to reinstall the removed hose
clamp, since it is unusable.
Do not replace the removed hose clamp with a
screw clamp or with other types of clamp.
3 - 15
3 - 16
WARNING
The throttle setting screws (1) are painted over
and cannot be adjusted.
Only if the entire cable fitting (2) is to be re-
placed, the setting screws can be adjusted.
The two M4x12 (3) screws securing the throttle
valve potentiometer are painted over and can
only be extracted if the sensor itself is being
removed.
- left injector;
3 - 17
WARNING
During rebody, make sure the two throttle con-
trol cable adjusters are correctly mounted to
their fittings and check/adjust their play.
3 - 18
WARNING
When removing the throttle body proceed with
care as it is still connected to the fuel tank via
the fuel hose.
When reassembling :
- the fuel delivery hose must not be twisted or squeezed
by other components; if it is damaged or degraded in
any way, it must be replaced;
- the fuel delivery hose must be positioned in such a way
as to reach the right hand side of the throttle body from
below, passing between the two intake flanges;
- the throttle body must be perfectly seated on the intake
flanges;
- the clips must be fully tightened down.
3 - 19
• Loosen and remove the two M6x16 screws (7) and re-
move the fuel pressure regulator (8) complete with O-
ring.
• Loosen and remove the three M6x25 screws (9) and
remove the left injector support (10) - together with the
relevant gasket (11), injector (12) and sealing ring (13)
- from the throttle body.
3 - 20
3 - 21
3 - 22
THROTTLE BODY
3 - 23
• Fit the new O-rings (1) and seals (2) on both injectors.
• Insert the injector (3) in the left injector support (4) and
in the right injector support (5).
• Fit the left injector support gasket (6), right injector
support gasket (7) and the two seals (8) on the throttle
body.
• Install the complete left injector support (4) and right in-
jector support (5) in the throttle body, fastening them
with the new M6x25 (9) (10) screws respectively.
• If the synchronizing screws (11) and respective O-rings
(12) have been replaced, tighten the screws (11) until
they touch the stop and then unscrew them a single
turn.
CAUTION
The precise adjustment of the screws (11) must
be performed using a vacuum gauge.
3 - 24
CAUTION
Make sure that the ends of the torsion spring
(20) are hooked onto the throttle cable support
bracket and pulley (21).
3 - 25
ASSEMBLY
• Fit the two bushes (3) and torsion spring (4) on the
throttle body.
• Fit the throttle valve control lever (2) on the throttle
valve spindle.
NOTE Spray a temporary lubricant on the spring (4).
CAUTION
Make sure the ends of the torsion spring (4) are
hooked on the throttle body and throttle valve
control lever (2).
3 - 26
CAUTION
If the minimum value measured is lower than
0.00394 in (0.1 mm), the throttle body must be
replaced.
CAUTION
If the minimum value measured is lower than
0.0059 in (0.15 mm), the throttle body must be
replaced.
3 - 27
ENGINE 4
4-1
SUMMARY
4.1. ENGINE ........................................................................................................................................................... 3
4.1.1. REMOVING THE ENGINE..................................................................................................................... 3
4.1.2. REINSTALLING THE ENGINE ............................................................................................................ 26
4.1.3. TIGHTENING TORQUES .................................................................................................................... 51
4-2
4.1. ENGINE
4.1.1. REMOVING THE ENGINE
4-3
4-4
4-5
4-6
4-7
4-8
4-9
• Remove the oil tank and extract the line coming from
the cooler.
4 - 10
• Undo the stud mounting the oil line clamp to the engine
casing
4 - 11
4 - 12
4 - 13
4 - 14
4 - 15
4 - 16
4 - 17
• Undo the four nuts fixing the manifold to the rear cylin-
der
4 - 18
4 - 19
4 - 20
• Undo the bolt securing the pinion and keep the wash-
ers
4 - 21
4 - 22
4 - 23
4 - 24
4 - 25
4 - 26
• Locate the rear left spacer and tighten the screw to the
prescribed torque.
4 - 27
4 - 28
4 - 29
• Fit the rear brake lever mount and pump and tighten
the screws to the specified torque
• Fit the rear brake lever and tighten the screws to the
specified torque
4 - 30
4 - 31
4 - 32
• Fit the pinion casing and guide plate and tighten the
screws to the specified torque
4 - 33
4 - 34
4 - 35
4 - 36
4 - 37
4 - 38
• Move the cooler towards the engine and refit the lower
mounts
4 - 39
4 - 40
4 - 41
• Screw in the stud mounting the oil line clamp to the en-
gine casing
4 - 42
• Fit the fairing air dam and tighten its screws (2 central
4 side).
4 - 43
4 - 44
4 - 45
4 - 46
4 - 47
4 - 48
4 - 49
4 - 50
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
ENGINE
4 - 51
CYCLE PARTS 5
5-1
SUMMARY
5.1. BODY PANELS ............................................................................................................................................... 4
5.1.1. REMOVING THE BODY PANELS ......................................................................................................... 4
5.1.2. BODY PANEL REASSEMBLY ............................................................................................................. 13
5.1.3. TIGHTENING TORQUES .................................................................................................................... 21
5.2. FRONT FORK ............................................................................................................................................... 22
5.2.1. DIAGRAM (RSV R) .............................................................................................................................. 22
5.2.2. REMOVING THE FORK LEGS ............................................................................................................ 24
5.2.3. FITTING THE FORK LEGS.................................................................................................................. 28
5.2.4. CHANGING THE FORK FLUID (RSV R) ............................................................................................. 31
5.2.5. TOPPING UP THE FORK FLUID (RSV R) .......................................................................................... 34
5.2.6. REPLACING THE OIL/DUST SEAL (RSV R) ...................................................................................... 37
5.2.7. REFITTING THE OIL/DUST SEAL (RSV R) ........................................................................................ 44
5.2.8. CHECKING THE COMPONENTS ....................................................................................................... 51
5.2.9. FRONT FORK DIAGRAM .................................................................................................................... 55
5.2.10. CHANGING THE FORK FLUID (RSV FACT) ...................................................................................... 56
5.2.11. TOPPING UP THE FORK FLUID (RSV FACT).................................................................................... 58
5.2.12. REPLACING THE OIL/DUST SEAL (RSV FACT)................................................................................ 60
5.2.13. TIGHTENING TORQUES .................................................................................................................... 63
5.3. STEERING BEARING ................................................................................................................................... 64
5.3.1. DIAGRAM ............................................................................................................................................ 64
5.3.2. CHECKING THE BEARING SLACK STEERING ................................................................................. 66
5.3.3. STEERING BEARING ADJUSTMENT................................................................................................. 67
5.3.4. TIGHTENING TORQUES .................................................................................................................... 71
5.4. REAR SUSPENSION .................................................................................................................................... 72
5.4.1. DIAGRAM ............................................................................................................................................ 72
5.4.2. REMOVING THE REAR SUSPENSION .............................................................................................. 73
5.4.3. CHECKING THE COMPONENTS ....................................................................................................... 77
5.4.4. REFITTING THE REAR SUSPENSION............................................................................................... 79
5.4.5. DISASSEMBLING THE REAR SUSPENSION LINKAGE .................................................................... 82
5.4.6. TIGHTENING TORQUES .................................................................................................................... 83
5.5. SWINGING ARM ........................................................................................................................................... 84
5.5.1. REMOVING THE SWINGING ARM ..................................................................................................... 84
5.5.2. CHECKING THE COMPONENTS ....................................................................................................... 87
5.5.3. DISASSEMBLING THE REAR FORK GASKETS ................................................................................ 88
5.5.4. REFITTING THE SWINGING ARM...................................................................................................... 89
5.5.5. TIGHTENING TORQUES .................................................................................................................... 92
5.6. FRONT WHEEL............................................................................................................................................. 93
5.6.1. DIAGRAM ............................................................................................................................................ 93
5.6.2. REMOVING THE WHEEL.................................................................................................................... 94
5.6.3. CHECKING THE FRONT WHEEL COMPONENTS............................................................................ 97
5.6.4. DISASSEMBLING THE FRONT WHEEL BEARINGS ......................................................................... 99
5.6.5. ASSEMBLING THE FRONT WHEEL BEARINGS ............................................................................. 100
5.6.6. REFITTING THE FRONT WHEEL ..................................................................................................... 102
5.7. REAR WHEEL ............................................................................................................................................. 104
5.7.1. DIAGRAM .......................................................................................................................................... 104
5.7.2. REMOVING THE REAR WHEEL ....................................................................................................... 105
5.7.3. REMOVING THE FINAL DRIVE UNIT ............................................................................................... 107
5.7.4. CHECKING THE REAR WHEEL COMPONENTS............................................................................. 109
5.7.5. DISASSEMBLING THE REAR WHEEL BEARINGS.......................................................................... 113
5.7.6. ASSEMBLING THE REAR WHEEL BEARINGS................................................................................ 114
5.7.7. DISASSEMBLING THE FINAL DRIVE UNIT BEARINGS .................................................................. 116
5.7.8. ASSEMBLING THE FINAL DRIVE UNIT BEARINGS ........................................................................ 117
5.7.9. REMOVING THE FLEXIBLE COUPLINGS........................................................................................ 118
5.7.10. REMOVING THE CROWN GEAR ..................................................................................................... 119
5.7.11. REFITTING THE REAR WHEEL ....................................................................................................... 120
5.7.12. TIGHTENING TORQUES .................................................................................................................. 122
5.8. FRONT BRAKE ........................................................................................................................................... 123
5.8.1. CHANGING THE FRONT BRAKE PADS (RSV R) ........................................................................... 123
5.8.2. CHANGING THE FRONT BRAKE PADS (RSV FACT)..................................................................... 124
5.8.3. CHECKING THE FRONT BRAKE DISCS.......................................................................................... 126
5.8.4. REMOVING THE FRONT BRAKE DISCS ......................................................................................... 127
5.8.5. BLEEDING THE BRAKE CIRCUIT .................................................................................................... 128
5.9. REAR BRAKE.............................................................................................................................................. 129
5.9.1. CHANGING THE REAR BRAKE PADS ............................................................................................. 129
5.9.2. CHECKING THE REAR BRAKE DISC............................................................................................... 130
5.9.3. REMOVING THE REAR BRAKE DISC .............................................................................................. 131
5-2
5.10. CLUTCH.......................................................................................................................................................132
5.10.1. BLEEDING THE CLUTCH CIRCUIT...................................................................................................132
5.11. DRIVE CHAIN ..............................................................................................................................................133
5.11.1. DRIVE CHAIN.....................................................................................................................................133
5.11.2. INSPECTING THE DRIVING CHAIN SHOE.......................................................................................135
5.11.3. REMOVING THE CHAIN SHOE .........................................................................................................136
5.11.4. LOWER CHAIN SHOE .......................................................................................................................138
5-3
5-4
5-5
5-6
• Undo the two screws securing the rider’s seat and lift it
off
5-7
• Undo the screw securing the belt and keep the center-
ing bushings
5-8
5-9
5 - 10
5 - 11
• Remove the tank and slide the cabling out of the frame
5 - 12
5 - 13
• Lower the tank and fit the two front retaining screws
5 - 14
5 - 15
• Secure the side panels to the tank and the seat sub-
frame
5 - 16
• Fit the spacers between the tail and the seat’s sub-
frame
5 - 17
5 - 18
• Insert the fairing from the side taking care not to dam-
age it
5 - 19
5 - 20
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
5 - 21
5 - 22
Key:
1. Retainer ring
2. Spring preload adjuster
3. Spring preload pusher
4. Slider upper plug
5. Washer
6. Slide bush
7. Piston assembly
8. Centering bush
9. Spring-press tube
10. Spring
11. Spring rest washer
12. Lower collar
13. Slider
14. Slide bush
15. Guide bush
16. Stop ring
17. Gasket
18. Retainer ring
19. Anti dust gasket
20. Wheel-holder tube
21. Copper washer
22. Center screw
23. O-ring
24. O-ring
5 - 23
5 - 24
5 - 25
• Support the fork leg and slacken the screws on the up-
per and lower plates
5 - 26
5 - 27
5 - 28
• Fit the seal washer and screw on the axle nut to the
specified torque
• Make sure the fork legs are aligned by pumping the
fork up and down
5 - 29
WARNING
After fitting the brake calipers, repeatedly operate
the front brake lever
5 - 30
5 - 31
5 - 32
5 - 33
5 - 34
5 - 35
5 - 36
5 - 37
5 - 38
5 - 39
5 - 40
5 - 41
5 - 42
5 - 43
• Fit the wiper seal, stop ring and seal ring to the stan-
chion tube.
5 - 44
• Now fit the ring, mobile bushing and, after removing the
tape, the fixed bushing
5 - 45
• Fit the slider to the stem and install the oil seal in its
correct position with the special tool
5 - 46
5 - 47
5 - 48
5 - 49
5 - 50
WARNING
NEVER straighten a curved tube, since its
structure would be weakened, thus making the
use of the vehicle quite dangerous.
SLIDER
Make sure that there are neither damages, nor cracks.
Otherwise, change it.
SPRING
Check the integrity of the spring, making sure that its length
does not exceed the limit value.
If the length does not correspond to the limit value, change
the spring.
5 - 51
- pumping element.
If excessive wear or any damage is noticed, change the
component in question.
CAUTION
Remove any accumulation of impurities from
the bushings, taking care not to scratch their
surfaces.
5 - 52
FORK RSV R
WARNING
Before adjusting, first set the fork to the stiff-
est setting [turn the adjusters (1-2) fully clock-
wise]. The notches on the adjusters (1-2)
provide convenient reference marks when set-
ting compression and rebound damping.
Rotate the adjusters (1-2) gradually changing
setting by one eighth of a turn at a time.
CAUTION
Racing settings may only be used during offi-
cial competitions or sports events authorized
by the competent authorities and taking place
in closed circuits or, anyway, away from pub-
lic roads.
The law forbids riding a vehicle with racing
settings on public roads and highways.
(*) clockwise
(**) counterclockwise
(***) Have this adjustment carried out exclusively by an Aprilia Official Dealer
5 - 53
WARNING
Before adjusting, first set the fork to the stiff-
est setting [turn the adjusters (1-2) fully clock-
wise]. The notches on the adjusters (1-2)
provide convenient reference marks when set-
ting compression and rebound damping.
Rotate the adjusters (1-2) gradually changing
setting by one notch at a time.
CAUTION
Racing settings may only be used during offi-
cial competitions or sports events authorized
by the competent authorities and taking place
in closed circuits or, anyway, away from pub-
lic roads.
The law forbids riding a vehicle with racing
settings on public roads and highways.
(*) clockwise
(**) counterclockwise
(***) Have this adjustment carried out exclusively by an Aprilia Official Dealer
5 - 54
Key:
1. Complete RH fork leg
2. Complete LH fork leg
3. Top cap
4. Spring
5. Fork overhaul kit
5 - 55
• Release the top cap (3) from the slider using the
special tool (A).
• Push down the spacer tube (4) and fit a wrench to the
nut to lock out damping cylinder rotation.
• Release and remove the top cap (3) while holding the
damping cylinder with the wrench.
• Remove the spacer tube (4).
5 - 56
5 - 57
5 - 58
• Use the special tool (A) to tighten the top cap (3) on
the slider.
• Adjust to obtain correct setting.
5 - 59
• Pry the dust seal (3) off the slider (2) levering with a
flat-blade screwdriver at various positions.
5 - 60
REFITTING
WARNING
Be careful to prevent dirt from entering slider
or stanchion.
Never reuse the fork fluid.
Replace:
- oil seal (5)
- dust seal (3)
NOTE Smear the oil seal (5) lightly with fork fluid before
installation.
• Fit the following components to the stanchion (1) in the
order: dust seal (3), retaining ring (4) and oil seal (5).
5 - 61
• Insert the retaining ring (4) into its groove in the slider
(2).
• Push the dust seal (3) into its seat in the slider (2) and
ensure it becomes properly seated.
• Grasp the stanchion and pump it up and down slowly
several times.
WARNING
The stanchion must slide freely in the slider, in
a smooth motion.
• Pour front fork fluid into the fork leg up to correct level.
5 - 62
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
FRONT SUSPENSION
Front fork
Fork leg on top yoke 1+1 M8 18,439 -
Fork leg on bottom yoke 2+2 M8 18,439 -
tighten first
Head stock nut (tighten first, then slacken) 1 M35x1 29,502 and then
slacken
tighten 2nd
Head stock nut (tighten down 2nd time) 1 M35x1 14,751
time
man. + 90
Head stock locknut 1 M35x1 -
grade
Top yoke cap 1 M29x1 73,756 -
SHOWA fork hub clamps 2+2 M8 18,226 -
OHLINS fork hub clamps 2+2 M6 8,851 -
Steering damper
Steering damper collar to frame 1 M6 7,376 Loctite 243
Steering damper rod on bottom yoke 1 M6 7,376 -
5 - 63
5 - 64
Key:
1. Upper bush
2. Washer
3. Upper plate
4. Lock ring
5. Lock washer
6. Adjuster ring
7. Anti dust gasket
8. Anti dust gasket
9. Bearings
10. Lower plate
11. Steering damper
5 - 65
5 - 66
5 - 67
5 - 68
5 - 69
5 - 70
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
FRONT SUSPENSION
Front fork
Fork leg on top yoke 1+1 M8 18,439 -
Fork leg on bottom yoke 2+2 M8 18,439 -
tighten first
Head stock nut (tighten first, then slacken) 1 M35x1 29,502 and then
slacken
tighten 2nd
Head stock nut (tighten down 2nd time) 1 M35x1 14,751
time
man. + 90
Head stock locknut 1 M35x1 -
grade
Top yoke cap 1 M29x1 73,756 -
SHOWA fork hub clamps 2+2 M8 18,226 -
OHLINS fork hub clamps 2+2 M6 8,851 -
Steering damper
Steering damper collar to frame 1 M6 7,376 Loctite 243
Steering damper rod on bottom yoke 1 M6 7,376 -
5 - 71
Key:
1. Shock absorber
2. Double conrod
3. Needle bearing
4. Oil seal
5. Piston pin
6. Screw
7. T bush
8. Self-locking nut
9. Single conrod comp.
10. Hex socket screw
11. Screw w/ flange
5 - 72
• Move the fuel lines away from the area over the rear
suspension assembly
5 - 73
5 - 74
5 - 75
5 - 76
CAUTION
Make sure that none of the components ap-
pear to be visibly distorted, broken, cracked
and/or dented. Replace any damaged com-
ponents
BEARINGS
Rotate the rollers by hand. Each should rotate smoothly
without jamming and/or noise. There should be no end play.
Any bearings featuring said defects should be changed.
CAUTION
Apply grease on the rollers.
SEALS
Make sure the seals are intact; should they prove damaged
or show excessive wear signs, change them.
SHOCK ABSORBER
Make sure that there are no oil leaks from the shock ab-
sorber and that its travel is smooth and gradual. If this is not
the case, change the shock absorber.
WARNING
The shock absorber contains pressurized ni-
trogen. To prevent the risk of an explosion,
keep it away from flames and/or sources of
heat. In the event the shock absorber is to be
replaced, discharge the nitrogen by pressing
the central core of the valve under the cap or
under the screw.
(*) clockwise
(**) counterclockwise
5 - 77
CAUTION
Racing settings may only be used during of-
ficial competitions or sports events author-
ized by the competent authorities and taking
place in closed circuits or, anyway, away
from public roads. The law forbids riding a
vehicle with racing settings on public roads
and highways.
5 - 78
5 - 79
• Fit the panel onto the frame over the cable bundles
5 - 80
5 - 81
5 - 82
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
REAR SUSPENSION
Shock absorber
Shock absorber to frame 1 M10 36,878 -
Linkages
Single conrod to frame 1 M10 36,878 -
Single / double conrod 1 M10 36,878 -
Double conrod swinging arm 1 M10 36,878 -
Double conrod / shock absorber 1 M10 36,878 -
5 - 83
WARNING
Do not operate the rear brake lever with the
brake caliper removed, or the brake caliper pis-
ton might fall out leading to loss of brake fluid.
5 - 84
• From the left side, release and remove the lower shock
absorber nut.
• Extract the screw from the other side.
WARNING
Take great care when removing the swinging
arm.
Support it at the front to prevent it from drop-
ping.
Place a wooden support beneath the front of
the swinging arm to keep it from dropping or
moving.
5 - 85
WARNING
Make sure the transmission chain does not get
entangled when removing the swinging arm.
5 - 86
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both seals.
Always replace the gaskets with gaskets of the
same type.
5 - 87
CAUTION
The bearings must be checked and, if neces-
sary, changed every time they are disassem-
bled.
CAUTION
The bearings must be checked and, if neces-
sary, changed every time they are disassem-
bled.
5 - 88
5 - 89
5 - 90
• Working from the right side, fit the lower shock ab-
sorber screw.
• Tighten down the nut from the opposite side.
• Fit the pinion cover and tighten down its three screws
• Refit the rear wheel and exhaust assembly.
• Adjust the tension of the transmission chain.
5 - 91
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
SWINGING ARM
Swinging arm spindle nut 1 M30x1,5 44,254 -
Swinging arm spindle adjuster bushing 1 M30x1,5 8,851 -
Swinging arm spindle nut 1 M20x1,5 66,38 -
Caliper support pin 1 M12 36,878 Loctite 243
Chain tensioner screw and nut 1+1 M8 man. -
Rear brake hose bracket 3 M5 2,95 -
Chain guard cover 2 M5 2,95 -
Chain shoe 2 M5 2,213 -
Chain guide plate 1 M5 2,213 -
Rear stand bushing 2 M6 7,376 -
Chain guide plate (nut) 1 M6 7,376 -
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
REAR SUSPENSION
Shock absorber
Shock absorber to frame 1 M10 36,878 -
Linkages
Single conrod to frame 1 M10 36,878 -
Single / double conrod 1 M10 36,878 -
Double conrod swinging arm 1 M10 36,878 -
Double conrod / shock absorber 1 M10 36,878 -
5 - 92
Key:
1. Wheel pin
2. Nut
3. Seal
4. Bearing
5. Inner spacer
6. Complete wheel
7. Snap ring
8. Right spacer
9. Washer
5 - 93
5 - 94
5 - 95
5 - 96
CAUTION
Make sure that all the components are intact,
particularly the following.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both seals.
Always replace the gaskets with gaskets of the
same type.
5 - 97
5 - 98
5 - 99
NOTE The complete insertion of the left bearing (6) will bring
the following components into contact:
- right bearing (5);
- spacer (4);
- left bearing (6).
CAUTION
After the contact with the right bearing (5) do
not push further, in order to avoid forcing the
snap ring (3).
NOTE Once the left bearing (6) has been inserted, check the
coaxiality of the following components:
- right bearing (5);
- spacer (4);
- left bearing (6).
5 - 100
5 - 101
• Fit the seal washer and screw on the axle nut to the
specified torque
• Make sure the fork legs are aligned by pumping the
fork up and down
5 - 102
WARNING
After fitting the brake calipers, repeatedly oper-
ate the front brake lever
5 - 103
Key:
1. Nut
2. Washer
3. Side spacers
4. Left chain tightener shoe
5. Bearings
6. Central spacer
7. Complete wheel
8. Snap ring
9. Seal
10. Right chain tightener shoe
11. Wheel pin
5 - 104
5 - 105
• Remove the entire wheel, sliding the disc out from the
brake caliper
5 - 106
CAUTION
Proceed with care. If the final drive unit (1) is
installed on the flexible coupling holder (2), do
not overturn or rotate the rear wheel in hori-
zontal position on the rear sprocket side (A),
since the final drive unit would come off and
fall down, with the risk of damaging the rear
sprocket (3).
NOTE Do not unscrew the five nuts (4). The whole final
drive unit must be extracted from the flexible coupling
holder.
• Working (B) with both hands on the outer diameter of
the sprocket (3), extract the final drive unit keeping it
parallel to the wheel axis.
REASSEMBLY
NOTE Keep the final drive unit parallel to the wheel axis. To
introduce the unit, insert the flexible couplings (5) in the cor-
responding seats on the flexible coupling holder (2).
• Working (C) with both hands on the outer diameter of
the sprocket (3), insert the final drive unit in the flexible
coupling holder (2).
NOTE Perform the operation described below only if the left
(6) and/or the right spacer ring (7) have come off their seats.
• Insert the left (6) and/or the right spacer ring (7) in the
respective seats, with the longer diameter towards the
outside of the vehicle.
5 - 107
5 - 108
CAUTION
Make sure that all the components are intact,
particularly the following.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both seals.
Always replace the gaskets with gaskets of the
same type.
5 - 109
5 - 110
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
WARNING
Always change both bearings.
Always replace the bearings with bearings of
the same type.
5 - 111
FLEXIBLE COUPLINGS
• Make sure the rubber elements (5) of the flexible cou-
plings are not damaged and/or do not show excessive
wear.
If slack is excessive:
• Change all the flexible coupling rubber elements (5).
WARNING
Always replace the flexible couplings with ones
of the same type.
SPROCKET
• Check the conditions of the sprocket teeth (7).
CAUTION
To prevent the untimely wear of the new com-
ponents, crown, pinion and drive chain must be
replaced all together.
5 - 112
5 - 113
NOTE The complete insertion of the left bearing (6) will bring
the following components into contact:
- right bearing (5);
- spacer (4);
- left bearing (6).
CAUTION
After the contact with the right bearing (5) do
not push further, in order to avoid forcing the
snap ring (3).
NOTE Once the left bearing (6) has been inserted, check the
coaxiality of the following components:
- right bearing (5);
- spacer (4);
- left bearing (6).
5 - 114
5 - 115
5 - 116
5 - 117
5 - 118
CAUTION
The self-locking nuts (3) must be replaced
every three removals of the sprocket.
Replace the self-locking nuts (3) with nuts of
the same type.
Reassembly:
• Insert the five threaded pins (2) in the sprocket (5).
• Assemble the sprocket holder on the sprocket-thread-
ed pins unit.
• Screw the five self-locking nuts (3) by hand.
CAUTION
It is forbidden to install the final drive unit (6)
on the wheel to tighten the self-locking nuts.
CAUTION
To protect the crown gear, install guards (in
wood or aluminum) on the vice jaws. Lock only
the crown gear in the vice, be careful not to
lock any other component of the final drive
unit.
5 - 119
• Fit the wheel axle together with right hand chain guide
shoe to the swing arm.
• Fit the rear wheel and insert the wheel axle into its seat
• Fit the left hand chain tightener shoe and thrust washer
to the axle
5 - 120
5 - 121
TORQUE (ftlb)
SCREW / NUT
QUANTITY
NOTES
DESCRIPTION
REAR WHEEL
Sprocket / Sprocket carrier 5 M10 36,878 -
Wheel axle nut 1 M25x1,5 88,507 -
5 - 122
CAUTION
Once the pads have been removed, do not pull
the brake lever as the caliper pins are liable to
come out of their slot: brake fluid will spill out.
CAUTION
Always change both pads and make sure that
they are correctly positioned inside the caliper.
WARNING
When released, the safety spring (1) must lock
the pin (2) and fit in the appropriate seats (A).
If the spring is positioned correctly, it will not
be possible to extract the pin (2); carry out a
check.
5 - 123
WARNING
This vehicle is equipped with a twin-disc front brake
(one disc on either side of the wheel).
Always change all brake pads of both front brake
calipers as a set.
Changing the brake pads of one front brake caliper
only will affect the stability and safety of the vehicle,
putting the safety of persons or property at risk or
leading to vehicle damage.
• Press the retaining clip (2) and extract the pin (3) from the
inside.
• Remove the retaining clip (2).
WARNING
Do not operate the brake lever with the brake pads
removed, or the brake caliper pistons might fall out
leading to loss of brake fluid.
• Fit new brake pads and ensure they become properly seated
in the caliper.
5 - 124
WARNING
The four brake pads must always be replaced to-
gether. Ensure they become properly seated in the
brake caliper.
DANGER
When released, the retaining clip (2) should become
correctly located into its seats to lock the pin (3) in
place.
When the clip is positioned correctly, the pin (3) will
not come off. Try to extract the pin to ensure clip
and pin are securely in place.
5 - 125
5 - 126
CAUTION
When reassembling, apply LOCTITE® 243 on
the thread of the brake disc screws (1).
5 - 127
• Operate the brake lever and open the pump bleed nip-
ple slightly to allow the air to escape.
• Close the nipple before reaching the lever’s full stroke
and repeat the operation until no more air issues from
the nipple.
5 - 128
CAUTION
Once the pads have been removed do not pull
the brake lever as the brake caliper pins are li-
able to come out of their slot: brake fluid will
spill out.
CAUTION
Before sliding out the pin (2), take note of the
positioning of the safety spring (3); when re-
assembling, it must be refitted in the same way.
• Pull out the pin (2) and retrieve the safety spring (3).·
• Extract the two pads (4).
CAUTION
Once the pads have been removed do not pull
the brake lever, as the caliper pins are liable to
come out of their slot: brake fluid will spill out.
CAUTION
Always change both pads and make sure that
they are correctly positioned inside the caliper.
5 - 129
5 - 130
CAUTION
When reassembling, apply LOCTITE® 243 on
the thread of the brake disc screws (1).
5 - 131
5.10. CLUTCH
5.10.1. BLEEDING THE CLUTCH CIRCUIT
• Connect the hose to the clutch pump bleed nipple.
• Operate the clutch lever and open the pump bleed nip-
ple slightly to allow the air to escape.
• Close the nipple before reaching the lever’s full stroke
and repeat the operation until no more air issues from
the nipple.
5 - 132
5 - 133
CAUTION
If chain rollers are damaged, chain link pins are
loose and/or any O-rings are missing or dete-
riorated, replace the drive chain and the front
and rear sprockets as a set.
Lubricate the chain frequently, especially if you
find any dry or rusty parts.
Warped or seized links must be lubricated and
repaired.
CAUTION
The drive chain links are fitted with O-rings that
retain the grease inside. Use the utmost care
when adjusting, lubricating, washing or
replacing the chain.
5 - 134
5 - 135
• Loosen and remove the two left rider foot peg cover
screws.
5 - 136
• Pull the lower part of the chain shoe out from the front.
5 - 137
CHECKING WEAR
5 - 138
COOLING SYSTEM 6
6-1
SUMMARY
6.1. COOLING SYSTEM ........................................................................................................................................ 3
6.1.1. DIAGRAM .............................................................................................................................................. 3
6.1.2. FILLING THE COOLING SYSTEM ........................................................................................................ 4
6-2
Key:
1. Radiator
2. Fans
3. Expansion reservoir
4. Filler cap
5. Three-way thermostatic valve
6. Three-way manifold
6-3
6-4
6-5
ELECTRICAL SYSTEM 7
7-1
SUMMARY
7.1. ELECTRICAL SYSTEM................................................................................................................................... 3
7.1.1. COMPONENT LOCATION..................................................................................................................... 3
7.1.2. ELECTRICAL EQUIPMENT CHECK TABLE ......................................................................................... 5
7.1.3. CAN LINE............................................................................................................................................. 14
7.1.4. IMMOBILIZER...................................................................................................................................... 16
7.1.5. WIRING DIAGRAM .............................................................................................................................. 18
7-2
7-3
Key:
7-4
7-5
2 LAMBDA SENSOR
oxygen sensor with heater
sensor voltage 0 to 0.9 V (across pins 3 and 4)
heater resistance 12.5 Ω (across pins 1 and 2 at 68°F)
3 CAMSHAFT SENSOR
hall effect sensor
power 12 V
square wave output, 1 pulse every 2 engine revolutions
7-6
6 FALL SENSOR
resistance 62 KΩ with sensor at installation position
resistance 0 Ω when rotated 90° relative to installation posi-
tion.
8 INJECTOR
resistance 15 Ω
7-7
9 IGNITION COIL
primary resistance 0.4-0.5 Ω
11 IMMOBILIZER ANTENNA
winding resistance 14 Ω
12 STARTING MOTOR
peak absorption 120 A
7-8
13 INTAKE FLAP
winding resistance 30 Ω
14 STEPPER
phase resistance 50 Ω
15 GENERATOR
three-phase generator
winding resistance 0.4 Ω
output voltage 75 V AC (measure with generator discon-
nected from electrical system and engine running at 4000
rpm)
16 RECHARGE VOLTAGE
voltage 13.8 V across battery terminals (with engine running
at 4000 rpm)
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17 FUEL PUMP
absorption 3.9 A
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19 ECU
ECU pinout
Connector A
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Connector B
20 HEAD LAMP
Low beam (halogen) 12 V – 55 W H11 x 2
High beam (halogen) 12 V – 55 W H11 x 2
Front parking light 12 V – 5W
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21 TAIL LIGHT
Number plate light 12 V – 5W
22 SECONDARY FUSES
A– From key to: lights relay, horn, parking lights (5A).
A– From key to: direction indicators, dashboard (5A).
C– From battery to: positive under key at ECU (5 A).
D– From battery to: speed sensor, fuel pump, relay,
starter, lambda sensor (15 A).
E– From battery to: fan relay, coils, injectors, intake flap,
camshaft sensor (15 A)
F– From ignition switch to: high beam, low beam (20 A).
IMPORTANT There are three spare fuses (G).
23 MAIN FUSES
H – battery recharge and vehicle loads (red and red/white
cables) + immobilizer (30 A).
I – injection loads (red and red/black cables) (30 A).
IMPORTANT There is one spare fuse (L).
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STARTING
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7.1.4. IMMOBILIZER
IMMOBILIZER
The vehicle is equipped with an immobilizer that stops the
engine from being started if the correct code is not entered.
The code is stored in the transponder in each of the two keys
supplied with the vehicle. An antenna, mounted in the igni-
tion switch that is directly connected to the ECU, reads the
transponder data.
The immobilizer is completely independent of the CAN.
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4. After each key has been stored, the system waits for a
new key for 20 seconds (led on continuously) after
which the procedure self-terminates (the led flashes
once for each key and then turns off).
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